scholarly journals Performance Study of EDM Process Parameters Using TiC/ZrSiO4 Particulate-Reinforced Copper Composite Electrode

2021 ◽  
pp. 547-556
Author(s):  
Duraisivam Saminatharaja ◽  
Suresh Periyakgounder ◽  
Mahalingam Selvaraj ◽  
Jamuna Elangandhi
Keyword(s):  
Process Parameters ◽  
Removal Rate ◽  
Optimization Techniques ◽  
Tool Electrode ◽  
Performance Study ◽  
Machining Performance ◽  
Peak Current ◽  
Sem Image ◽  
Pulse On Time ◽  
Edm Process

Electrical discharge machines (EDM) are widely employed in machining components containing complex profiles of hard-to-cut and machining materials. However, the fabrication-of-tool time for the EDM process is excessively high in the traditional machining method, which significantly affects the machining rate. Therefore, in this paper, a powder metallurgy (PM) technique is employed to fabricate the tool electrode using copper (Cu), titanium carbide (TiC), and zirconium silicate (ZrSiO4) for different combinations. An L18 orthogonal array (OA) is planned using the following input parameters: three types of tools (Cu, Cu90, Cu80), peak current (PC) [A], pulse on time (PT) [µs], and gap voltage (GV) [V]. The performance of EDM is evaluated through the material removal rate (MRR), tool wear rate (TWR), and surface roughness (SR). The process parameters are optimized using two different techniques: the technique for order of preference by similarity to the ideal solution (TOPSIS) and grey relational analysis (GRA). TOPSIS and GRA optimization techniques produce the same optimal parametric solution for less TWR, SR, and higher MRR with the combination of the Cu90 tool, E8 APC, 15 µs pulse PT, and 75 V GV. Based on the ANOVA table of TOPSIS, pulse on time plays a major role, contributing 46.8 % of the machining performance; peak current shows the most significant contribution of 39.3 % of the machining performance using GRA values. Furthermore, the scanning electron microscope (SEM) image analyses are carried out on the machined workpiece surface to understand the effect of tools on machining quality.

scholarly journals Comparative Study of Optimization Models for Evaluation of EDM Process Parameters on Ti-6Al-4V

Modelling ◽  
2021 ◽  
Vol 2 (4) ◽  
pp. 555-566
Author(s):  
JagadeeswaraRao Maddu ◽  
Buschaiah Karrolla ◽  
Riyaaz Uddien Shaik ◽  
Srikanth Vuppala
Keyword(s):  
Comparative Study ◽  
Process Parameters ◽  
Electrode Materials ◽  
Removal Rate ◽  
Design Procedure ◽  
Optimization Techniques ◽  
Information Divergence ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

In this paper, different optimization techniques such as multi-objective optimization based on ratio analysis, the -nD angle, information divergence and multi-angle optimization methods were considered for comparative study in order to check their variation in results. These four techniques were considered asthese techniques were made from completely different methodologies, such as MOORA, is one of the latest multi-criteria decision-making methods that cover the weakness of other older methods and the latter three (-nD angle, Information Divergence and MAOT) methods are based on trigonometric methodologies. These optimization techniques were carried out using the effect of EDM process parameters viz., material removal rate and surface roughness as output parameters and current, pulse on time, pulse off time and different electrode materials as input process parameters. These parameters were obtained from the experiments modelled according to the Taguchi experimental design procedure in which the L18 orthogonal array was used to perform experimentation with the material of titanium alloy (Ti-6Al-4V). All the optimization techniques have obtained similar results among which -nD angle and Information Divergence technique tend to be easier and understandable for any similar application. The latter two methods avoid complexity and can be used for optimizing any relevant manufacturing process parameters such as the parameters of EDM, additive manufacturing, etc.

Investigations on Effect of Electrode Polarity on Machining Performance of Ti-5Al-2.5Sn Alloy Using Electric Discharge Machining Process

2016 ◽  
Vol 1137 ◽  
pp. 39-51 ◽  
Author(s):  
Sanjeev Kumar ◽  
Rupinder Singh ◽  
Ajay Batish ◽  
T.P. Singh
Keyword(s):  
Removal Rate ◽  
Machining Process ◽  
Performance Criteria ◽  
Tool Electrode ◽  
Micro Hardness ◽  
Machining Performance ◽  
Peak Current ◽  
Electrode Polarity ◽  
Pulse On Time ◽  
Pulse Off Time

In electrical discharge machining (EDM) process, electrode polarity plays an important role during machining operation. This paper addresses the issues of EDM utilizing the positive and negative tool-electrode polarity to explore the effects on the performance criteria such as material removal rate (MRR), tool wear rate (TWR), surface roughness (SR) and micro-hardness during machining of Ti–5Al-2.5Sn (GradeVI) Ti alloy. The Ti-5Al-2.5Sn alloy was machined using copper-chromium electrode with positive and negative polarity by varying the peak current and pulse-on-time, while the pulse-off-time was kept constant. The result of study suggests that reverse polarity improves the MRR, TWR, SR while normal polarity improves the surface micro-hardness. The peak current has the maximum affect on machining performance for both types of polarities. Further the migration of different elements and formation of compounds on the machined surface was investigated using EDX and XRD analysis.

Study on Ultrasonic Vibration in Gas and Optimization of a Novel Process of EDM

2013 ◽  
Vol 675 ◽  
pp. 365-369 ◽  
Author(s):  
Yan Cherng Lin ◽  
Han Ming Chow ◽  
Hai Ping Tsui ◽  
Yuan Feng Chen
Keyword(s):  
Ultrasonic Vibration ◽  
Process Parameters ◽  
High Efficiency ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Main Process ◽  
Machining Parameters ◽  
Machining Performance ◽  
Dielectric Fluids ◽  
Edm Process

The aim of this study is to investigate the machining characteristics of ultrasonic vibration assisted electrical discharge machining (EDM) process using gas media as the dielectric fluids. The process parameters were designed based on Taguchi method to conduct the experimental works. The main process parameters such as machining polarity, peak current, pulse duration, air pressure, working time, and servo reference voltage were chosen to determine their effects on machining performance in terms of material removal rate and surface roughness for SKD 61 tool steels. The experimental response values were transferred to signal-to-noise (S/N) ratios, and then the significant machining parameters associated with the machining performance were examined by analysis of variance (ANOVA). Therefore, the technique of ultrasonic vibration assisted EDM process in gas media was established with the concerning features related to environmentally friendly, high efficiency, and high machining quality to fit the demands of modern manufacturing applications.

Optimization of Process Parameters on Ti-6Al-4V Using Central Composite Design Method

2011 ◽  
Vol 189-193 ◽  
pp. 1393-1400 ◽  
Author(s):  
M.M. Rahman
Keyword(s):  
Surface Roughness ◽  
Wear Rate ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Peak Current ◽  
Long Pulse ◽  
Pulse On Time

Electrical discharge machining (EDM) is relatively modern machining process having distinct advantages over other machining processes and able to machine Ti-alloys effectively. This paper attempts to investigate the effects of process parameters on output response of titanium alloy Ti-6Al-4V in EDM utilizing copper tungsten as an electrode and positive polarity of the electrode. Mathematical models for material removal rate (MRR), electrode wear rate (EWR) and surface roughness (SR) are developed in this paper. Design of experiments method and response surface methodology techniques are implemented. The validity test of the fit and adequacy of the proposed models has been carried out through analysis of variance. It can be seen that as the peak current increases the TWR decreases till certain ampere and then increases. The excellent surface finish is investigated in this study at short pulse on time and in contrast the long pulse duration causes the lowest EWR. Long pulse off time provides minimum EWR and the impact of pulse interval on EWR depends on peak current. The result leads to wear rate of electrode and economical industrial machining by optimizing the input parameters. It found that the peak current, servo voltage and pulse on time are significant in material removal rate and surface roughness. Peak current has the greater impact on surface roughness and material removal rate.

Effect of Process Parameters in Electric Discharge Machining of Ti-6Al–4V Alloy by Three Different Tool Electrode Materials

2012 ◽  
Vol 488-489 ◽  
pp. 876-880 ◽  
Author(s):  
Manoj Kumar Kuttuboina ◽  
A. Uthirapathi ◽  
Singaravelu D. Lenin
Keyword(s):  
Process Parameters ◽  
Electrode Material ◽  
Electrode Materials ◽  
Metal Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Copper Electrode ◽  
Tool Electrode ◽  
Good Surface ◽  
Pulse On Time

The effect of process parameters namely peak current, pulse on time and flushing pressure on electrical discharge machining (EDM) of titanium alloy (Ti–6Al–4V) were investigated by using three different tool electrode materials namely copper, brass, and aluminium. Kerosene is used as dielectric. The process parameters for machining Ti6Al4V are varied at three levels by using Taguchi's orthogonal array table. The responses such as Metal Removal Rate (MRR), Tool Wear Rate (TWR), and Surface Roughness (SR) are measured and the most significant parameter was confirmed by ANOVA (Analysis Of Variance). The test result shows that copper electrode material possesses higher MRR, less TWR as compared to brass and aluminium. Brass and copper tools has good surface finish as compared with aluminium. The finest electrode material for machining of Ti6Al4V alpha beta alloy in EDM process was in the order of copper, brass and aluminium.

Sensitivity analysis and optimization of EDM process parameters

2019 ◽  
Vol 43 (1) ◽  
pp. 13-25 ◽  
Author(s):  
Uvaraja Ragavendran ◽  
Ranjan Kumar Ghadai ◽  
Akash Kumar Bhoi ◽  
Manickam Ramachandran ◽  
Kanak Kalita
Keyword(s):  
Sensitivity Analysis ◽  
Process Parameters ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Statistical Significance ◽  
Empirical Models ◽  
Optimization Techniques ◽  
Pulse On Time ◽  
Pulse Off Time

Electrical discharge machining (EDM) is a broadly used nonconventional material removal process for the machining of conductive work material irrespective of their hardness. In this article, empirical models for material removal rate (MRR) and surface roughness (Ra) of the workpiece are developed based on the extensive experiments performed on a special steel (WP7V) workpiece using a copper electrode. To account for the various parameters, an experimental design based on response surface methodology (RSM) is conducted considering three different factors namely — current, pulse-on-time, and pulse-off-time, each having three different levels. Analysis of variance (ANOVA) is conducted to test the statistical significance of the proposed empirical models. It is essential to determine the relationship and significance of input–output variation. Thus a sensitivity analysis is conducted. The interaction effect of input variables is also studied. Two different state-of-art optimization techniques, namely genetic algorithm (GA) and particle swarm optimization (PSO), are applied to predict the optimal combination of process parameters. Finally, multi-objective optimization is also carried out to simultaneously maximize MRR while minimizing Ra.

scholarly journals Parametric optimization of Edm on Hastelloy C-276 Using Taguchi L18 Technique

2018 ◽  
Vol 7 (2.7) ◽  
pp. 714 ◽  
Author(s):  
SK Khadar Basha ◽  
Murahari Kolli ◽  
M V.Jagannadha Raju
Keyword(s):  
Process Parameters ◽  
Discharge Current ◽  
Removal Rate ◽  
Extreme Environments ◽  
Industrial Applications ◽  
Dielectric Fluid ◽  
Machining Performance ◽  
Current Electrode ◽  
Pulse On Time ◽  
Pulse Off Time

Due to development in machining science the use of composites and alloys is a great deal for every industry. Hastelloy C276 the most versatile corrosion resistant nickel based super alloy which is used for industrial applications is considered for doing the            experiments .The high nickel and molybdenum content provides better corrosion resistance at extreme environments. In this report, the experiments are performed by using Taguchi L18 technique and their results are used for performance of each process parameters on their output responses. The process parameters considered for experimentation are discharge current, pulse- on- time, type of electrode and pulse off time for the output responses of material removal rate and surface roughness. Eco-friendly (drinking water) is used as a dielectric fluid. The experiments are designed and conducted using Taguchi L18 technique and analyze the influence of each process parameters on machining performance characteristics. Further, mathematical equations were developed using the statistical software MINITAB17.0.ANOVA is used for analyzing the experimental results obtained. It was observed from the response table that the average values of MRR and SR for pulse on time, discharge current, electrode are identified as important process parameters.  

Optimization of Machining Parameters in Rotary EDM Process Using Copper Tungsten Electrode

2015 ◽  
Vol 813-814 ◽  
pp. 368-375
Author(s):  
Suddala Chandramouli ◽  
Kesha Eswaraiah
Keyword(s):  
Process Parameters ◽  
Electric Discharge ◽  
Removal Rate ◽  
Machining Parameters ◽  
Tungsten Electrode ◽  
Electric Discharge Machining ◽  
Input Parameters ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Edm Process

Electrical Discharge Machining is a thermo-electric process and one of the advanced methods of machining. Most publications on the EDM process are directed towards non-rotational tools, but rotation of the tool provides a good flushing in the machining zone. In this study, the optimal setting of the process parameters on Rotary Electric Discharge machining (REDM) was determined. The important process parameters that have been selected are peak current, pulse on time, pulse off time and rotational speed of tool with output response as Material Removal Rate (MRR).Taguchi experimental design (L27 orthogonal array) was used to formulate the experimental layout and experiments were conducted on Hardened stainless steel machined with copper tungsten electrode. ANOVA method was used with the help of MINITAB 17 software to analysis the influence of input process parameters on the MRR using Rotary Electric Discharge Machining. The input parameters were optimized in order to obtain maximum MRR, The results of the present work revealed that proper selection of input parameters will play a significant role on MRR.

scholarly journals Experimental Investigation of Edm Die Sinking Process Parameters on Aluminium Alloy 5083 Using Design of Experiment

2017 ◽  
Vol 4 (1) ◽  
pp. 138-144
Author(s):  
Wahaizad Safiei ◽  
Muhamad Ridzuan Radin Muhamad Amin
Keyword(s):  
Surface Roughness ◽  
Aluminium Alloy ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Design Of Experiment ◽  
Material Removal ◽  
Removal Rate ◽  
Peak Current ◽  
Pulse On Time ◽  
Pulse Off Time

In this paper, the results of surface roughness (Ra) and material removal rate (MRR) are presented based on experimental studies of Electrical Discharge Machining (EDM) process parameters. Pulse ON time, pulse OFF time, peak current, gap voltage and jump speed are the selected input parameters and the experiments were conducted with Aluminium Alloy 5083 as a workpiece, copper as an electrode and the response variables are surface roughness (Ra) and material removal rate (MRR). Design of Experiment and Analysis of Variance (ANOVA) were applied to identify the optimum settings.The result shows that the significant factors for the value of surface roughness (Ra) and material removal rate (MRR) are pulses ON time and peak current.

Performance Evaluation of Dry EDMed Aluminium Alloy

2015 ◽  
Author(s):  
M. Pradeep Kumar ◽  
N. Pragadish
Keyword(s):  
Surface Roughness ◽  
Aluminium Alloy ◽  
Removal Rate ◽  
Research Work ◽  
Work Piece ◽  
Tool Electrode ◽  
Dry Edm ◽  
Input Parameters ◽  
Pulse On Time ◽  
Edm Process

In this research work, experiments were conducted using Electrical Discharge Machining (EDM) in dry and conventional mode, and the results were compared and analyzed. LM13 Aluminium alloy is used as the workpiece and pure cylindrical copper rod is used as the tool electrode. Since the machining was difficult in dry EDM, some modifications were made in the existing tool design to conduct the experiments in dry EDM. The experiments were designed using Taguchi’s L27 orthogonal array. Discharge current (I), gap voltage (V), pulse on time (TON), pressure (P) and speed (N) were chosen as the various input parameters. Three levels of values were chosen for each input parameter, whereas speed was chosen as the fixed parameter. The variation in the material removal rate (MRR), surface roughness (SR), surface morphology and elemental composition of the machined surface due to variation in the input parameters were analyzed in both dry and conventional mode. Better MRR, and surface roughness were observed in the work piece machined under conventional EDM process. The MRR is observed to be 84% more in the conventional mode when compared with dry EDM. Also, when compared to the dry EDM, about 15.33% better SR values is observed in the conventional EDM process.

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